140M and 150 Motor Grader Power Train Transmission - Assemble Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected always.

Note: Lubricate all seal rings and O-ring seals prior to assembly.

Note: Check the O-ring seals, and the seals for wear or for damage. Replace the components, if necessary.

Note: Remove old anaerobic sealant from the bottom of the blind tapped holes in housing (237) before assembling.

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Illustration 1	g01389210
This Illustration is viewed from the bottom.

1. Install filter (246) and O-ring seal (245). Position cover (244) and install bolts (243). Tighten bolts (243) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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   Illustration 2	g01389019

2. Position plate (241) and install bolts (242). Tighten bolts (242) to a torque of 12 ± 3 N·m (106 ± 27 lb in).

3. Lower the temperature of bearing outer races (240), (239), and (238). Install bearing outer races (240), (239), and (238) into housing (237).
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   Illustration 3	g01389010

4. Install the O-ring seals and covers (236) onto housing (49). Tighten the bolts for covers (236) to a torque of 28 ± 7 N·m (21 ± 5 lb ft). Install the O-ring seals and covers (235) onto housing (49). Tighten the bolts for covers (235) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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   Illustration 4	g01394193

5. Lower the temperature of races (234) and races (233) . Install races (234) and races (233) into housing (49).
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   Illustration 5	g01394189

6. Install O-ring seal (232).
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   Illustration 6	g01394188

7. Raise the temperature of bearing (231). Install bearing (231). Install retaining ring (230).
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   Illustration 7	g01394185

8. Install gear (229).

9. Install retaining ring (228).
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   Illustration 8	g01394184

10. Install retainer (227). Install bearing (226). Install retaining ring (225).
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    Illustration 9	g01394180

11. Install gear (224). Install bolts (223). Tighten bolts (223) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 10	g01394236

12. Use two people to position shaft assembly (130) onto Tooling (H). The weight of input shaft assembly (130) is approximately 25 kg (55 lb). Use suitable blocking to support input shaft assembly (130). Install retaining ring (222) (not shown) onto input shaft assembly (130). Install gear (221). Raise the temperature of inner bearing (220). Install inner bearing (220) onto input shaft assembly (130).
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    Illustration 11	g01394368

13. Use a suitable lifting device to position input shaft assembly (130) to housing (237). The weight of input shaft assembly (130) is approximately 23 kg (50 lb). Use Tooling (N) to install retaining ring (219) onto input shaft assembly (130). Install ring seal (218).
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    Illustration 12	g01388797

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    Illustration 13	g01394379

14. Install seal rings (217) and (216) onto piston (215).
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    Illustration 14	g01388786

15. Install piston (215) and valve assembly (214) onto clutch assembly (174).
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    Illustration 15	g01388754

16. Install friction discs (213) and clutch plates (212) onto clutch assembly (174). Install friction disc (211), spring (210), and hub assembly (207) onto clutch assembly (174).
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    Illustration 16	g01388732

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

17. Use Tooling (L) to compress hub assembly (207). Install two half rings (209) (not shown) and lock rings (208) onto clutch assembly (174).
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    Illustration 17	g01388726

18. Position washer (205) to clutch assembly (174). Apply Tooling (T) to screws (206). Install screws (206). Tighten screws (206) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
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    Illustration 18	g01388685

19. Install thrust disc (204) and roller bearing assembly (203) onto clutch assembly (174).
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    Illustration 19	g01388678

20. Install gear assembly (202), thrust disc (201), thrust disc (200), and thrust race (199) onto clutch assembly (174). Raise the temperature of inner bearing (198). Install inner bearing (198) onto clutch assembly (174).

21. Use a suitable lifting device to turn over clutch assembly (174) onto Tooling (H). The weight of clutch assembly (174) is approximately 43 kg (95 lb).
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    Illustration 20	g01388663

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    Illustration 21	g01394424

22. Install seal rings (196) and (197) onto piston (195).
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    Illustration 22	g01388653

23. Install piston (195) and valve assembly (194) onto clutch assembly (174).
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    Illustration 23	g01388635

24. Install friction discs (191), clutch plates (192), friction discs (193), spring (190), and hub assembly (187) onto clutch assembly (174).
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    Illustration 24	g01388624

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

25. Use Tooling (L) to compress hub assembly (187). Install two half rings (189) (not shown) and lock rings (188).
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    Illustration 25	g01388618

26. Position washer (185) to clutch assembly (174). Apply Tooling (T) to screws (186). Install screws (186). Tighten screws (186) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
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    Illustration 26	g01388614

27. Install thrust disc (184) and roller bearing assembly (183) onto clutch assembly (174).
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    Illustration 27	g01388597

28. Install gear assembly (182), thrust disc (181), and thrust disc (180) onto clutch assembly (174). Raise the temperature of inner bearing (179). Install inner bearing (179) onto clutch assembly (174).
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    Illustration 28	g01394545

29. Attach Tooling (R) and a suitable lifting device to clutch assembly (174). The weight of clutch assembly (174) is approximately 64 kg (140 lb). Use Tooling (R) and the suitable lifting device to install clutch assembly (174) to housing (237).
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    Illustration 29	g01388581

30. Install O-ring seals (177) and seal rings (178) onto seal carrier (176).
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    Illustration 30	g01388568

31. Position seal carrier (176) onto clutch assembly (174). Install bolts (175). Tighten bolts (175) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 31	g01388470

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    Illustration 32	g01394550

32. Install seal rings (173) and (172) onto piston (171).
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    Illustration 33	g01388335

33. Install piston (171) and valve assembly (170) onto clutch assembly (135).
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    Illustration 34	g01388330

34. Install friction discs (169), clutch plates (168), friction disc (167), spring (166), and hub assembly (163) onto clutch assembly (135).
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    Illustration 35	g01388324

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

35. Use Tooling (L) to compress hub assembly (163). Install two half rings (165) (not shown) and lock rings (164).
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    Illustration 36	g01388320

36. Position washer (162) to clutch assembly (135). Apply Tooling (T) to screws (161). Tighten screws (161) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
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    Illustration 37	g01388296

37. Install thrust disc (160) and roller bearing (159) onto clutch assembly (135).
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    Illustration 38	g01388277

38. Install gear assembly (158). thrust disc (157), thrust disc (156), and thrust race (155) onto clutch assembly (135). Raise the temperature of inner bearing (154). Install inner bearing (154) onto clutch assembly (135).

39. Use a suitable lifting device to turn over clutch assembly (135) onto Tooling (H). The weight of clutch assembly (135) is approximately 41 kg (90 lb).
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    Illustration 39	g01388246

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    Illustration 40	g01394572

40. Install seal rings (153) and (152) onto piston (151).
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    Illustration 41	g01394574

41. Install piston (151) and wave spring (150) onto clutch assembly (135).
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    Illustration 42	g01388240

42. Install clutch plates (149), friction discs (148), and hub assembly (145).
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    Illustration 43	g01388208

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

43. Use Tooling (L) to compress hub assembly (145). Install two half rings (147) (not shown) and lock rings (146).
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    Illustration 44	g01388185

44. Lower the temperature of bearing (144). Install bearing (144) into gear assembly (141).
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    Illustration 45	g01388168

45. Install washer (143), thrust disc (142), gear assembly (141), thrust disc (140), and spacer (139) onto clutch assembly (135).
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    Illustration 46	g01394607

46. Install gear (138) and spacer (137) onto clutch assembly (135). Raise the temperature of inner bearing (136). Install inner bearing (136).
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    Illustration 47	g01394616

47. Attach Tooling (R) and a suitable lifting device to clutch assembly (135). The weight of clutch assembly (135) is approximately 61 kg (135 lb). Use Tooling (R) and the suitable lifting device to install clutch assembly (135) into housing (237).
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    Illustration 48	g01394625

48. Install O-ring seals (134) and seal rings (133) onto seal carrier (132).
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    Illustration 49	g01394631

49. Position seal carrier (132) onto clutch assembly (135). Install bolts (131). Tighten bolts (131) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 50	g01394649

50. Install gear (129) onto input shaft assembly (130). Raise the temperature of inner bearing (128). Install inner bearing (128) onto input shaft assembly (130).
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    Illustration 51	g01387858

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    Illustration 52	g01394705

51. Install seal rings (127) and (126) onto piston (125).
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    Illustration 53	g01394707

52. Install piston (125) and wave spring (124) onto clutch assembly (60).
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    Illustration 54	g01387846

53. Install clutch plates (123), friction discs (122), and hub assembly (119).
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    Illustration 55	g01387824

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

54. Use Tooling (L) to compress hub assembly (119). Install two half rings (121) (not shown) and lock rings (120).
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    Illustration 56	g01387820

55. Install washer (118) and thrust disc (117).
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    Illustration 57	g01387765

56. Lower the temperature of bearing (116). Install bearing (116) into gear assembly (115).
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    Illustration 58	g01394711

57. Install gear assembly (115) and thrust disc (114) onto clutch assembly (60).
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    Illustration 59	g01394713

58. Install gear (113) and thrust disc (112) onto clutch assembly (60). Raise the temperature of inner bearing (111). Install inner bearing (111) onto clutch assembly (60).

59. Use a suitable lifting device to turn over clutch assembly (60) onto Tooling (H). The weight of clutch assembly (60) is approximately 54 kg (120 lb).
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    Illustration 60	g01387580

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    Illustration 61	g01394729

60. Install seal rings (110) and (109) onto piston (108).
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    Illustration 62	g01387573

61. Install piston (108) and wave spring (107) onto clutch assembly (60).
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    Illustration 63	g01387556

62. Install clutch plates (106), friction discs (105), and hub assembly (102) onto clutch assembly (60).
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    Illustration 64	g01387541

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

63. Use Tooling (L) to compress hub assembly (102). Install two half rings (104) (not shown) and lock rings (103).
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    Illustration 65	g01387528

64. Install washer (101) and thrust disc (100) onto clutch assembly (60).
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    Illustration 66	g01387526

65. Lower the temperature of sleeve bearing (99). Install sleeve bearing (99) into gear assembly (98).
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    Illustration 67	g01387520

66. Install gear assembly (98) and thrust disc (97) onto clutch assembly (60).
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    Illustration 68	g01394799

67. Install gear (96) and thrust disc (95) onto clutch assembly (60). Raise the temperature of inner bearing (94). Install inner bearing (94) onto clutch assembly (60).
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    Illustration 69	g01394809

68. Install seal rings (93) and (92) onto piston (91).
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    Illustration 70	g01394820

69. Install seal ring (89) onto balance piston (88).
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    Illustration 71	g01394812

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

70. Install piston (91), springs (90), and balance piston (88) onto clutch assembly (59). Use Tooling (N) to install retaining ring (87) onto clutch assembly (59).
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    Illustration 72	g01387232

71. Install clutch plates (86), friction discs (85), and hub assembly (84).
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    Illustration 73	g01387228

72. Install lock rings (83), half rings (82), washer (81), and thrust disc (80).
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    Illustration 74	g01394862

73. Install gear assembly (79), thrust disc (78), and thrust washer (77). Raise the temperature of bearing (76). Install bearing (76).

74. Use a suitable lifting device to turn over clutch assembly (59). The weight of clutch assembly (59) is approximately 59 kg (130 lb).
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    Illustration 75	g01394871

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    Illustration 76	g01387093

75. Install seal rings (74) and (75) onto piston (73). Install piston (73) and wave spring (72).
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    Illustration 77	g01387088

76. Install clutch plates (71), friction discs (70), and hub assembly (67).
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    Illustration 78	g01386997

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

77. Use Tooling (L) to compress hub assembly (67). Install two half rings (69) (not shown) and lock rings (68).
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    Illustration 79	g01386993

78. Install thrust washer (66).
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    Illustration 80	g01386992

79. Lower the temperature of bearing sleeves (65). Install bearing sleeves (65) into gear assembly (63).
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    Illustration 81	g01386841

80. Install gear assembly (63) and thrust washer (64).
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    Illustration 82	g01394888

81. Raise the temperature of rotor (62). Install rotor (62) onto clutch assembly (59).

82. Raise the temperature of bearing (61). Install bearing (61) onto clutch assembly (59).
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    Illustration 83	g01386815

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    Illustration 84	g01386811

83. Attach Tooling (J) and a suitable lifting device to clutch assembly (59) and clutch assembly (60). The combined weight of clutch assembly (59) and clutch assembly (60) is approximately 163 kg (360 lb). Use Tooling (J) and the suitable lifting device to move clutch assembly (59) and clutch assembly (60) from Tooling (H) to the housing.
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    Illustration 85	g01395925

84. Install seal rings (57) and O-ring seals (58) to seal carrier (56). Repeat for the remaining seal carrier.
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    Illustration 86	g01386795

85. Position seal carrier (56) and install bolts (55). Tighten bolts (55) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

86. Position seal carrier (54) and install bolts (53). Tighten bolts (53) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 87	g01386792

87. Install the O-ring seal and tube assembly (52). Install bolts (51) and the locks. Tighten bolts (51) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 88	g01386764

88. Attach Tooling (A) and Tooling (C) to housing (49). The weight of housing (49) is approximately 136 kg (300 lb).

89. Use Tooling (A), Tooling (C), and the suitable lifting device to position housing (49). Install bolts (48). Tighten bolts (48) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 89	g01386757

90. Position speed sensors (47) and (46). Install bolts (45). Tighten bolts (45) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 90	g01386749

91. Install cover (44).
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    Illustration 91	g01386747

92. Position speed sensors (43) and (42). Install bolts (41). Tighten bolts (41) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 92	g01386730

93. Position speed sensor (39) and guard (40). Install bolt (38). Tighten bolt (38) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 93	g01386684
    This Illustration shows the transmission with the output shaft downward.

94. Attach Tooling (A), Tooling (C), Tooling (F), and a suitable lifting device to transmission (1). Use Tooling (A), Tooling (C), Tooling (F), and the suitable lifting device to position transmission (1) onto Tooling (B) and Tooling (E) with the output shaft upward. The weight of transmission (1) is approximately 861 kg (1900 lb).
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    Illustration 94	g01386675

95. Install hub (37) and retaining ring (36).
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    Illustration 95	g01386663

96. Install dowels (35) and O-ring seals (34).

97. Install clutch plates (33) and friction discs (32).
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    Illustration 96	g01386662

98. Install seal (31).
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    Illustration 97	g01395990

99. Install O-ring seal (30), O-ring seal (29), O-ring seal (28), O-ring seal (27), and O-ring seal (26) onto solenoid (25).
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    Illustration 98	g01386646

100. Install solenoid (25). Install pressure sensor (24) and the O-ring seal. Tighten pressure sensor (24) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).
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     Illustration 99	g01386632

101. Use two people to install housing (23). The weight of housing (23) is approximately 20 kg (45 lb).
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     Illustration 100	g01386624

102. Install guard (20). Connect harness assembly (21) and harness assembly (19).
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     Illustration 101	g01396019

103. Install piston seal (18) and piston seal (17) onto piston (16).
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     Illustration 102	g01386610

104. Install piston (16) and O-ring seal (15).
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     Illustration 103	g01386599

105. Install coned disc springs (14). Use Tooling (D) to install retaining ring (13).
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     Illustration 104	g01386589

106. Install lip seal (12).
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     Illustration 105	g01386585

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     Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

107. Position plate assembly (11). Install bolts (10). Tighten bolts (10) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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     Illustration 106	g01386579
     This Illustration shows the transmission with the output shaft upward.

108. Attach Tooling (A), Tooling (C), and a suitable lifting device to transmission (1). The weight of transmission (1) is approximately 853 kg (1880 lb).
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     Illustration 107	g01386575

109. Install O-ring seal (9) and cup (8). Install retaining ring (7).
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     Illustration 108	g01386574

110. Install yoke assembly (6).
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     Illustration 109	g01386565

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     Illustration 110	g01386568

111. Attach Tooling (A) and a suitable lifting device to transmission (1). The weight of transmission (1) is approximately 857 kg (1890 lb). Use Tooling (A) and the suitable lifting device to position transmission (A) onto Tooling (B).

112. Position spacers (5) and control module (4). Install bolts (3). Tighten bolts (3) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

113. Install hose assembly (2).

End By:

1. Install the transmission.